The Corolla AE86 H2 Concept and Corolla AE86 BEV Concept are two classic Toyota sports cars with zero emission powertrains. What improvements did Gazoo Racing engineers have to make to use a hydrogen internal combustion engine and battery electric drive in 40-year-old cars?
This is not only entertainment for engineers, but also a plan for the future. Toyota launched the AE86 Carbon Neutral project to offer similar solutions to collectors and car enthusiasts who want to transform their classic cars into zero-emission cars in the future. One of the favorite cars of Toyota fans was chosen for the modification. The sporty, rear-wheel drive Corolla AE86 in the Trueno version (with opening headlights) received a hydrogen drive, and the second copy with a Levin body was converted into a battery electric car.
Corolla AE86 H2 Concept: 40-year-old hydrogen engine
In building the Corolla AE86 H2 prototype, Toyota used the experience gained from converting new GR Yaris and GR Corolla sports cars into hydrogen-powered cars and launching the latter in Japan’s Super Taikyu endurance racing series. The highlight of the work was the adaptation of the classic 1.6-liter 4A-GEU engine, which is standard on the AE86, to burn hydrogen. Unlike electric vehicles, which run on batteries or fuel cells, hydrogen-powered vehicles can use gasoline-driven components.
Toyota Gazoo Racing engineers had to do without digital support, because they did not have a 3D model at their disposal. The 4A-G engine was developed four decades ago. This means that for the young and middle generation of Toyota engineers, this was a completely unknown design.
“The original 4A-G engine came on the market when I was in elementary school. I came across a lot of solutions that I didn’t know about before. However, we have been able to combine them with the hydrogen engine technology we have developed for the current GR Yaris H2 and GR Corolla H2 engines,” said Jun Miyagawa, engineer specializing in emission-free drives.
Technology from Toyota Mirai and hydrogen-powered GR Yaris
The team began by carefully studying the 4A-G engine, as well as studying many different privately owned AE86s. Toyota engineers have kept modifications to the classic rear-wheel drive Corolla to a minimum. Changes to the 4A-GEU engine included fuel injectors, fuel lines and spark plugs. The original exhaust system and muffler were modified accordingly, and two high-pressure hydrogen tanks from Toyota Mirai were installed in place of the fuel tank.
The hydrogen-powered Corolla AE86 H2 Concept rides like a standard petrol car and weighs just 995kg after modifications, 55kg more than the original. Acceleration is comparable to the classic AE86 petrol version.
– The reaction to pressing the accelerator pedal is exactly the same. The engine sound and vibration also give the same feeling. I already noticed this when I rode the hydrogen-powered GR Corolla in the Super Taikyu races. Hydrogen is a truly new form of energy that makes the hopes for a brighter future for the automotive industry a reality,” commented Masahiro Sasaki, Toyota Gazoo Racing driver, during the first test drive.
Corolla AE86 BEV Concept: electric drive and manual transmission
Unlike the hydrogen car, which had modified the original production engine, the AE86 BEV concept received a completely different type of drive, which entailed far-reaching changes to its internal structure. At the same time, they did not require modifications to the platform and body. This means that in the future, when the automotive industry becomes completely emission-free, thanks to the replacement of the original drive with an electric one, classic cars will be able to continue to serve their owners.
This project was a unique opportunity for the team to combine the strengths of the sporty Corolla AE86 with the advantages of electric drive and Lexus’ expertise in developing electric vehicles based on the Lexus Electrified concept. In their willingness to experiment, Toyota and Lexus engineers went so far as to leave a manual transmission in the car, adapting it to work with an electric motor.
Driving pleasure is a priority
Toyota decided not to increase the capacity of the battery. The advantage of the original Corolla AE86 is its low weight, so the team decided to install a battery that would not put too much stress on the car. Driving pleasure and sportiness were more important in this project than a long range.
The weight of the rear-mounted battery is offset by the front-mounted engine, making the car perfectly balanced, just like the original model. At the same time, the electric units are very lively, as they produce maximum torque in the full speed range, so the car gives an amazing driving experience, which is confirmed by the words of the test drivers.
- The feeling is amazing. The AE86 BEV has excellent acceleration. The motor works like a normal 4A-G motor. The power is comparable, but the maximum torque available at all times makes for an even better driving experience. It rides sideways, as it should be, because the AE86 is a drifting legend,” says Masahiro Sasaki.
Source: Wprost
I am Jason Root. I work in the news website industry and mostly cover the automobile industry. I have also written for Daily News Hack. My work revolves around new car models, prices, and features. In addition, I often write about used cars and tips for buying them. My articles are meant to be helpful for those who are in the market for a new or used car.
